JP2013023171A - Interior trim part for vehicle and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior trim part for a vehicle and a method of manufacturing the same, for further improving joining strength between a base material and a welding member.SOLUTION: This method of manufacturing the interior trim part for the vehicle includes: a first process of arranging a composite film 5 of respectively sticking hot melt films 9 and 11 having a thickness of 10-50 μm to both surfaces of metallic foil 7 of 20-200 μm between the base material 1 and the welding member 3; a second process of arranging an electromagnetic induction heating device 21 in a state of setting a distance between an under surface 23a of an electromagnetic induction heating device body 23 and an upper surface 1a of the base material 1 to 15 mm or less; a third process of heating a metallic foil part 7 in the composite film 5 by making a high frequency current flow to the electromagnetic induction heating device 21; and a fourth process of joining the base material 1 and the welding member 3 via the composite film 5 by melting the hot melt film parts 9 and 11 in the composite film 5 by heat of the metallic foil part 7.

Description

  The present invention relates to a vehicle interior part and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, various interior parts are mounted in order to improve the appearance of a vehicle interior (see, for example, Patent Document 1).

  The clip mounting bracket, which is an interior part described in Patent Document 1, has an adhesive attached to the back side. On the other hand, an interior material has a base material and the low melting-point fiber web layer provided in the surface of this base material. Then, when electromagnetic induction heating is performed in a state where the clip mounting bracket is placed on the surface of the interior material, the adhesive, the low melting point fiber web layer, and the base material are softened, so that the clip mounting bracket becomes the interior material. Be joined.

Japanese Patent Laid-Open No. 10-16657

  However, in the said patent document 1, since the thickness of the adhesive agent and the clip mounting bracket is not specifically specified, there was a problem that the bonding strength between the clip mounting bracket and the interior material is not always sufficient.

  Then, an object of this invention is to provide the interior component for vehicles which further improves the joint strength of a base material and a welding member, and its manufacturing method.

  A method for manufacturing an interior component for a vehicle according to the present invention is a method for manufacturing an interior component for a vehicle in which a welding member is attached to a base material made of a synthetic resin using electromagnetic induction heating. A first step of disposing a composite film in which a hot melt film having a thickness of 10 to 50 μm is bonded to both surfaces of a metal foil having a thickness of 20 to 200 μm, a lower surface of the electromagnetic induction heating device main body, and an upper surface of the welding member A second step of disposing the electromagnetic induction heating device in a state where the distance is set to 15 mm or less, a third step of supplying a high-frequency current to the electromagnetic induction heating device to generate heat in the metal foil portion of the composite film, and the metal And a fourth step of melting the hot melt film portion of the composite film by heat of the foil portion and joining the base material and the welding member through the composite film. It is characterized by that.

  In the present invention, since the thickness of the metal foil and the hot melt film in the composite film is set in an appropriate range, the bonding strength between the base material and the welding member can be improved.

It is sectional drawing which shows roughly the 1st process in the manufacturing method of the vehicle interior component by embodiment of this invention. It is sectional drawing which shows roughly the initial stage of the 2nd process in the manufacturing method of the interior component for vehicles. It is sectional drawing which shows roughly the 3rd process and the 4th process in the manufacturing method of the interior component for vehicles. 1 is a cross-sectional view schematically showing an interior part for a vehicle according to an embodiment of the present invention. The test piece in the Example of this invention is shown, (a) is a front view of a test piece, (b) is a side view of a test piece.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the present embodiment, a member made of a thermoplastic resin is used as a base material, and a clip or bracket made of a synthetic resin is used as a welding member, but the present invention is not limited to these, and is widely applied to the entire interior part for a vehicle. Applicable.

  The vehicle interior part manufacturing method according to the present embodiment is a manufacturing method in which a welding member is attached to a base material made of synthetic resin using electromagnetic induction heating.

  Specifically, a first step of disposing a composite film composed of a metal foil and a hot melt film between the base material and the welding member, and a lower surface of the electromagnetic induction heating device main body and an upper surface of the base material A second step of disposing the electromagnetic induction heating device in a state where the distance is set to 15 mm or less; a third step of supplying a high-frequency current to the electromagnetic induction heating device to generate heat in the metal foil portion of the composite film; and the metal foil A fourth step of melting the hot melt film portion of the composite film by the heat of the portion and joining the base material and the welding member through the composite film. Hereinafter, characteristics of each process will be described.

[First step]
As shown in FIG. 1, in the first step, the base material 1 is disposed on the lower side, the welding member 3 is disposed on the upper side, and the composite film 5 is interposed between the base material 1 and the welding member 3. .

  The substrate 1 is made of a thermoplastic resin, such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), acrylonitrile-styrene-butadiene (ABS), polycarbonate (PC), polyvinyl chloride (PVC), Resins such as high density polystyrene (HPS) are possible. Only one of the thermoplastic resins may be used, or a thermoplastic resin selected from two or more may be used.

  As the welding member 3, a general injection part can be applied, and examples thereof include a clip, a bracket, a reinforcement, a striker, a net, and a cushion material (foam). The material of the welding member 3 is made of, for example, a thermoplastic resin, such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), acrylonitrile-styrene-butadiene (ABS), polycarbonate (PC), polyvinyl chloride. (PVC), high density polystyrene (HPS), ethylene vinyl acetate (EVA), polyester, polyacetal (POM), polyamide (PA), and the like are applicable.

  The composite film 5 is formed by bonding hot melt films 9 and 11 to both surfaces of a metal foil 7. The thickness of the metal foil 7 is 20 to 200 μm. Moreover, the thickness of the hot melt films 9 and 11 is 10 to 50 μm.

  As the metal foil 7, for example, aluminum or iron is preferable. In the case of aluminum, the thickness is preferably 20 to 50 μm, and in the case of iron, the thickness is preferably 80 to 200 μm.

  When the thickness of aluminum is less than 20 μm, it becomes too thin and the heat generation amount of the metal foil 7 due to electromagnetic induction is insufficient, so that the hot melt films 9 and 11 are not sufficiently melted. As a result, since the adhesive force by the hot melt films 9 and 11 is lowered, it is not preferable. On the other hand, if it is thicker than 50 μm, the amount of heat generation becomes too large and burnt is generated.

  On the other hand, when the thickness of iron is less than 80 μm, the hot melt films 9 and 11 are not sufficiently melted because the iron foil becomes too thin and the heat generation amount of the metal foil 7 due to electromagnetic induction is insufficient. As a result, since the adhesive force by the hot melt films 9 and 11 is lowered, it is not preferable. On the other hand, if it is thicker than 200 μm, the amount of heat generation becomes too large and burnt is generated.

  Moreover, when the thickness of the hot melt films 9 and 11 is less than 10 μm, the amount of the hot melt films 9 and 11 is too small and the adhesive strength is lowered, which is not preferable. When the thickness of the hot melt films 9 and 11 is larger than 50 μm, the amount of the hot melt films 9 and 11 protrudes too much, resulting in poor appearance and high cost.

  As the material of the hot melt films 9 and 11, polyamide resin, polyester resin, PP resin, PE resin, or the like can be applied. In addition, it is preferable to use the same material as either the base material 1 or the welding member 3. Moreover, it is also possible to apply copper, zinc, tin, magnesium and alloys thereof as the metal foil 7.

[Second step]
Next, in the second step, the electromagnetic induction heating device 21 is disposed above the welding member 3 as shown in FIG.

  As shown in FIG. 2, the electromagnetic induction heating device 21 is provided with a main body portion 23 at a lower portion, and a coil 25 is spirally wound in the main body portion 23. Here, as shown in FIG. 3, the distance D between the lower surface 23a of the main body 23 and the upper surface 1a of the substrate 1 is set to 15 mm or less. When the distance D is larger than 15 mm, the Joule heat of the metal foil portion 7 in the composite film 5 becomes too small even when a high frequency current is passed through the coil 25, and the melting amount of the hot melt film 9.11. For this reason, since the adhesive force by the composite film 5 falls, it is not preferable.

[3rd process, 4th process]
In the third step, lines of magnetic force are generated around the coil 25 when a high-frequency current is passed through the coil 25 provided in the electromagnetic induction heating device 21. Due to the magnetic lines of force, an eddy current flows through the metal foil portion 7 in the composite film 5 and the metal foil portion 7 is heated by Joule heat.

  In the fourth step, as shown in FIG. 3, the hot melt film portions 9 and 11 in the composite film 5 are melted by the heat of the metal foil portion 7, and the base material 1 and the welding member 3 form the composite film 5. Are joined together. When the predetermined time elapses, the composite film 5 is cooled and the hot melt film portions 9 and 11 are cured, and the vehicle 1 in which the substrate 1 and the welding member 3 are joined via the composite film 5 as shown in FIG. The interior part 31 is completed.

  Next, examples of the present invention will be described.

[Example 1]
A tensile shear test was performed using the test piece 41 shown in FIG. Two plate-shaped PP resins 43 and 45 (thickness: 2 mm) having a length of 70 mm and a width of 20 mm are prepared, and a 20 × 20 mm joining portion 49 is joined by electromagnetic induction heating through the composite film 47. The test piece 41 was used. Here, the frequency was 20 kHz, the applied pressure during bonding was 0.5 MPa, the energization time was 4 seconds, and the interface temperature was 140 ° C. Thereafter, the two synthetic resins 43 and 45 were pulled up and down at 340 N to verify whether or not they were torn. In Example 1, the metal foil in the composite film 47 was aluminum. Moreover, the distance (refer FIG. 3) of the lower surface of an electromagnetic induction heating apparatus main-body part and the upper surface of PP resin arrange | positioned below was 5 mm.

  In Table 1, ◯ indicates a case where fracture occurred at a portion other than the joined portion with a pulling force of 340N. Moreover, x shows the case where it peeled off at the joint portion during pulling or the case of poor appearance. Specifically, when the thickness of the hot melt was 5 mm, the amount of hot melt was too small and the adhesive strength was insufficient. When the thickness of the hot melt was 60 mm, the amount of the hot melt was too large to protrude, resulting in poor appearance. When the thickness of the metal foil made of aluminum was 10 μm, the calorific value was insufficient, and the hot melt was not sufficiently melted, resulting in insufficient adhesion. When the thickness of the metal foil was 70 μm, the calorific value was too large, and burnt was generated, resulting in poor appearance.

[Example 2]
Next, Example 2 will be described. In Example 2, the same test piece as in Example 1 was used. However, the only difference is that the metal foil in the composite film is iron, and the distance between the lower surface of the electromagnetic induction heating device main body and the upper surface of the PP resin disposed on the lower side is 15 mm.

  In Table 2, when the thickness of the hot melt was 5 mm, the amount of the hot melt was too small and the adhesive strength was insufficient. When the thickness of the hot melt was 60 mm, the amount of the hot melt was too large to protrude, resulting in poor appearance. When the thickness of the metal foil made of iron was 40 μm, the calorific value was insufficient and the hot melt was not sufficiently melted, resulting in insufficient adhesion. When the thickness of the metal foil was 240 μm, the calorific value was too large, and burnt was generated, resulting in poor appearance.

  Below, the effect by this embodiment is demonstrated.

(1) The method for manufacturing an interior part for a vehicle according to the present embodiment includes a hot melt film 9 having a thickness of 10 to 50 μm on both surfaces of a metal foil 7 having a thickness of 20 to 200 μm between the base material 1 and the welding member 3. 11 and the electromagnetic induction heating device 21 in a state where the distance between the lower surface 23a of the electromagnetic induction heating device main body 23 and the upper surface 1a of the substrate 1 is set to 15 mm or less. The composite film 5 is formed by a second step of arranging a high frequency current through the electromagnetic induction heating device 21 to heat the metal foil portion 7 of the composite film 5 and heat of the metal foil portion 7. A fourth step of melting the hot melt film portions 9 and 11 and joining the base member 1 and the welding member 3 via the composite film 5.

  Thus, since the thickness of the metal foil 7 and the hot melt films 9 and 11 in the composite film 5 is set in an appropriate range, the bonding strength between the base material 1 and the welding member 3 can be improved.

  For example, when the thickness of the hot melt films 9 and 11 is less than 10 μm, the amount of the hot melt films 9 and 11 is too small and the adhesive strength is lowered, which is not preferable. When the thickness of the hot melt films 9 and 11 is larger than 50 μm, the amount of the hot melt films 9 and 11 protrudes too much, resulting in poor appearance and high cost.

  Further, when the distance D between the lower surface 23a of the main body 23 and the upper surface 1a of the base material 1 is greater than 15 mm, the Joule heat of the metal foil portion 7 in the composite film 5 becomes too small even when a high frequency current is passed through the coil 25. The melting amount of the hot melt film 9.11. For this reason, since the adhesive force by the composite film 5 falls, it is not preferable.

(2) The metal foil part 7 in the composite film 5 is made of aluminum and has a thickness of 20 to 50 μm.

  When the thickness of aluminum is less than 20 μm, it becomes too thin and the heat generation amount of the metal foil 7 due to electromagnetic induction is insufficient, so that the hot melt films 9 and 11 are not sufficiently melted. As a result, since the adhesive force by the hot melt films 9 and 11 is lowered, it is not preferable. On the other hand, if it is thicker than 50 μm, the amount of heat generation becomes too large and burnt is generated.

(3) The metal foil part in the said composite film consists of iron, and thickness is 80-200 micrometers.

  When the thickness of iron is less than 80 μm, it becomes too thin and the heat generation amount of the metal foil 7 due to electromagnetic induction is insufficient, so that the hot melt films 9 and 11 are not sufficiently melted. As a result, since the adhesive force by the hot melt films 9 and 11 is lowered, it is not preferable. On the other hand, if it is thicker than 200 μm, the amount of heat generation becomes too large and burnt is generated.

DESCRIPTION OF SYMBOLS 1 ... Base material 1a ... Upper surface 3 ... Welding member 5 ... Composite film 7 ... Metal foil 9, 11 ... Hot melt film 23 ... Electromagnetic induction heating apparatus main-body part 23a ... Lower surface 31 ... Interior component for vehicles

Claims (4)

A method for manufacturing an interior part for a vehicle in which a welding member is attached to a base material made of synthetic resin using electromagnetic induction heating,
A first step of disposing a composite film in which a hot melt film having a thickness of 10 to 50 μm is bonded to both surfaces of a metal foil having a thickness of 20 to 200 μm between the base material and the welding member;
A second step of disposing the electromagnetic induction heating device in a state where the distance between the lower surface of the electromagnetic induction heating device main body and the upper surface of the substrate is set to 15 mm or less;
A third step of causing a high-frequency current to flow through the electromagnetic induction heating device to heat the metal foil portion in the composite film;
A fourth step of melting the hot melt film portion of the composite film by heat of the metal foil portion and joining the base material and the welding member via the composite film, .   The method for manufacturing an interior component for a vehicle according to claim 1, wherein the metal foil portion in the composite film is made of aluminum and has a thickness of 20 to 50 µm.   The method for manufacturing an interior part for a vehicle according to claim 1, wherein the metal foil portion in the composite film is made of iron and has a thickness of 80 to 200 μm.   The interior part for vehicles produced by the method of any one of the said Claims 1-3.

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